Pile carpet strip with a sponge rubber backing and method of making same



FILE CARPET TRIP WITH A SPONGE MUBBER BACKING AND METHOD OF MAKING SAME Filed July 14, 1948 23, 1949- i A T. DILDILIAN 2,480,004

' Ara fox/man Zii'urzzeg Patented Aug. 23, 1949 PILE CARPET STRIP WITH A SPONGE RUB- BER BACKING AND METHOD OF MAKING SAME Ara. T. Dildilian, Suifield, Conn., assignor to Bigelow-Sanford Carpet 00., Inc., Thompsonville, Conn., a corporation of Massachusetts Application July 14, 1948, Serial No. 38,630

8 Claims.

This invention relates to a pile carpet strip with a sponge rubber backing having its edges so prepared as to facilitate assembling and seaming and to a method of preparing those edges. The principal object of the invention is to enable the assembling of cut pieces of such carpet strips together on a floor, with their pile faces up, accurately and rapidly. Another object is to facilitate such assembling with the lay of the pile of the pieces of strips in the same direction,

The drawing is a diagrammatic weftwise crosssection of a pile carpet strip having a resilient cellular or sponge rubber backing, and of the component threads.

The resilient cellular or sponge rubber backing may be attached to the back of the fabric in any suitable manner, as by cementing it thereto, but I prefer the weave illustrated in the drawing. In this instance the roots I of the pile are embedded in the sponge rubber backing 2 and are looped about the holding weft shots 3, the stufier warps 5 are between the upper and lower wefts, and the binder warps I pass over the upper weft shots and under the lower weft shots. In each selvage the stuifers, the binder warp and the selvage cord are enclosed by the weft loops. The sponge rubber penetrates the back of the fabric and binds the threads together so that the fabric may be cut without fraying.

Preferably I insert but one stuffer warp between the third and fourth pile rows 8 and 9 on each side of the carpet, leaving in the body of the carpet the usual two or more stuifer warps between adjacent rows of pile warps. I prefer that the single stufier warp be of cotton or its equivalent rather than of jute or its equivalent. If the single stuifer is of jute, I prefer it to be single ply or no more than two-ply. By this construction I increase the facility with which a clean out can be made between the third and fourth rows of pile warps and I avoid the danger of cutting through a jute stuifer warp and of leaving undesirable pieces of jute along the cut edges of the pieces to be assembled.

I prepare the carpet for assembling with other pieces of carpet by cutting through the pile face of the carpet between the pile rows where there is a single stufier adjacent to its sides nearly, but not entirely, through the sponge rubber backing, as shown at Ill. Then, when the operator is ready to assemble the pieces of carpet, all he need do is to tear the portions outside of the cuts of! both sides of the carpet, as indicated at the right of the figure, thereby producing cut carpet edges which are in perfect condition for assembling.

' When the rubber is out nearly through there is not enough rubber left when the border is torn on to leave a jagged edge but the torn edge is smooth and even. It is an advantage in handling and transporting the carpet to maintain the edges integral with the body of the carpet so that the parts, where the cut is made, are remote from the borders and are protected from abuse.

I have found it of assistance in cutting the carpet in the row where there is a single stuffer warp to weave the pile warps between that row and the edge, on each side of the carpet, of different colors from one another and from the color of the pile in the body of the carpet so that the differences in color serve as guides in the cutting. Moreover, such differences in color serve as an index of the lay of the pile. Pile lay is a distinctive characteristic of woven floor coverings as the pile loops or tufts tend to lay over slightly in the direction of the wire motion side of the loom. This lay is so slight that unless the carpet has an index of some kind it requires close inspection and feel to determine the direction of the pile lay. Nevertheless it is important for the appearance of the entire carpet that in assembling and seaming the pieces of carpet together the lay of the pile in the several pieces shall be the same. The use of the difierent colors in the warp rows at the sides of the carpet enables the operator, who is assembling the pieces of carpet, to determine at a glance the lay of the pile in the pieces so that he may unite the pieces with the lay of the pile the same throughout the assembled carpet.

My carpet with sponge rubber backing has the following advantages:

1. Facilitating and expediting installations by the cuts between pile rows adjacent to the sides of the carpet so that the border portions may be readily torn off and leave out edges ideal for assembling and seaming.

2. Protecting the edges to be eventually joined from soiling and injury during handling, transportation, display, storage, etc., by providing outer border portions which are eventually discarded.

3. Facilitating the cutting of the carpet between two pile rows adjacent to the edge of the carpet by the omission of one or more of the stuffers between those'rows.

v 4. A pile lay index on the pile face of the carpet formed by the contrasting colored pile yarns at the edges of the fabric.

I claim:

1. The method of preparing the edge of a carpet having a backing of resilient cellular rubber which comprises weaving the carpet with the usual pairs of stuffer warps in the body or the carpet and with but one stufier warp between two rows of pile warps adjacent to a side of the carpet, and cutting the carpet warpwise between said rows of pile warps to a depth nearly but not entirely through-the resilient cellular rubber.

2. The method of preparing the edge of a piece of pile carpet having a backing'of resilient cellular rubber which comprises weaving rows of pile warps adjacent to a side of the carpet of a different color from the color of the pile warps in the body of the carpet and cutting the carpet warpwise between adjacent rows of pile warps of different colors through the back of the carpet and nearly but not entirely through the resilient cellular rubber. I I

3. A pile carpet strip having a resilient cellular rubber backing and comprising a body portion and side portions, the side portions being partially separated from the body portion by warpwise cuts which extend through the fabric backing of the strip and nearly but not entirely through the resilient cellular rubber backing, said cuts being between warp pile rows where there is a less number of stufier warps than the number of stufier warps in the rows in the body portion of the strip.

4. A pile carpet strip having a resilient cellular rubber backing and comprising a body portion and side portions, the side portions being partially separated from the body portion by warpwise cuts which extend through the fabric backing ofthe strip and nearly but not entirely through the resilient cellular rubber backing, said cuts being between warp pile rows where there are a less number of stuffer warps than the number of stufier warps in the rows of the body of the strip, the rows of pile warps in one side portion being of one color and the rows of pile warps in the other side portion being of a difierent color and the pile in the body of the strip being of a different color from the colors of the pile rows in the side portions of the strip.

5. A pile carpet strip having a resilient cellular rubber backing and comprising a body portion and a side portion, the side portion being partially 6. A pile carpet strip having a resilient cellular rubber backing and comprising a body portion and side portions, the side portions being partially separated from the body portion by warpwise cuts which extend through the fabric backing of the strip and nearly but not entirely through the resilient cellular rubber backing, the pile warps of one side portion being of a color different from the color or the pile warps of the other side portion and from the color of the pile warps of the body portion.

'7. The method of preparing the edge of a piece of pile carpet having a backing of resilient cellular rubber which comprises weaving rows of pile warps adjacent to a side of the carpet of a different color from the color of the pile warps in the body of the carpet, weaving rows of pile warps adjacent to the opposite side of the carpet of a different color from the color of the pile warps in the body of the carpet and from the color of the pile warps of the other side, and cutting the carpet at each side warpwise between adjacent rows of pile warps of difierent colors through the back of the carpet and nearly but not entirely through the resilient cellular rubber.

8. A pile carpet strip comprising a layer of pile carpet, having a woven backing and a pile face, and a layer of resilient cellular rubber secured to the back of the woven backing, said strip having a body portion and relatively narrow side portions, the side portions being partially separated from the body portion by warpwise cuts parallel to the edgesof the carpet which extend through the fabric backing of the strip and nearly but not entirely through the resilient cellular rubber backing whereby the side portions remain attached to the body portion to protect the cut edges but can be torn off of the body portion to prepare it for seaming.

ARA T. DILDILIAN.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,842,746 Chance Jan. 26, 1932 1,871,046 Dickie Aug. 9, 1932 2,209,247 Dildilian July 23, 1940 

